DEFINE

This function allows the user to read in CAD model or finite element model. If the imported CAD data is a solid model with thickness information, the user can use the MIDDLE SURFACE, or SEPARATE SURFACE function to generate the desired surfaces. Then use the UNFOLD FLANGE function to unfold the flange on the generated surfaces.

Define Flange

Once the user clicks on the ADD button in FLANGE group, a dialog box appears, as shown in Figure 6.1.2. Click on SURFACE(S) to select flange surfaces, and then enter a part name in the TO PART field, as shown in Figure 6.1.3. Click APPLY to create a new flange part. The user can also click add part button to add the selected flange surfaces to another existing part. At the same time, the program will automatically add this part to the flange list, as shown in Figure 6.1.4. Besides, the user can also use the RENAME and REMOVE buttons in FLANGE group to rename the flange part or delete the flange part.

                     

Figure 6.1.2  Select Flange Surface                                      Figure 6.1.3  Create Flange Part

 89

Figure 6.1.4  Add Flange Part

Define Die

Click on the ADD button in TOOL group to define some parts as die. In addition, the user can also click on the RENAME and REMOVE buttons to rename the die part and delete the die part. After defining the die, the font color of DEFINE will change from red to black, as illustrated in Figure 6.1.5.

Figure 6.1.5  Define die

6.1.1.1  IMPORT

This function allows the user to read in CAD or finite element model data into active database. Please refer to Section 3.6  for detailed information about the Import function.

 

6.1.1.2  MIDDLE SURFACE

This function allows user to create the mid surface from a solid part. For more information please refer to the Section 5.2.7.

 

6.1.1.3  SEPARATE SURFACE

This function is used to separate the top and bottom surface layers of sheet metal parts with the thickness information. For more information please refer to the Section 5.2.8.

 

6.1.1.4  UNFOLD FLANGE

This function unfolds flanges on a part so the user can create an addendum with an unfolded part trim line.

 

Figure 6.1.6  Unfold flange

There are two methods to unfold flange, as illustrated in Figure 6.1.6.

·         Geometric Unfold

This function unfolds the selected flange surface to the plane where base surface locates. Once the function is selected, eta/DYNAFORM opens the SELECTED SURFACE dialog box to select flange surfaces to be unfolded.  Refer to Figure 6.1.7 for typical surfaces with the defined flange highlighted.

Figure 6.1.7  Select Flange Surface

·         After selecting surfaces, the DFE module will determine and highlight the unfold line and the boundary line. As shown in Figure 6.1.8, the bold line is the unfold line, and the other is the boundary line of the base surface and unfolded surface.  eta/DYNAFORM displays a SELECT OPTION dialog box as illustrated in Figure 6.1.9. The user has to select an option to continue operation.

Figure 6.1.8  Unfold Line and Boundary Line

4

Figure 6.1.9  Select Option dialog box

·         If the unfold line and boundary line are correct, select ACCEPT to continue. The program will unfold the selected surfaces along the unfold line and continue to the next step.

 

If the unfold line is not correct, select RETRY.  eta/DYNAFORM will use a different method to find the desired unfold line and boundary line. If ADJUST GAP TOLERANCE is selected, the dialog box as illustrated in Figure 6.1.10 is displayed to allow the user to change the gap tolerance between surfaces.

5

Figure 6.1.10  Input Gap dialog box

The default gap tolerance is 2.5.  If there are small surfaces in the part, a smaller gap tolerance should be used. If SELECT BASE SURFS is selected, eta/DYNAFORM allows the user to select surfaces as the base surfaces.  A base surface is a surface that connects the flange surfaces along the unfold line.

 

24

Figure 6.1.11  Input Bent Angle dialog box

 

The unfolded surfaces are automatically stored in a new part named UNFOLDED.

 

Figure 6.1.12  Unfolded Flange

5

Figure 6.1.13  Control Keys dialog box

 

SMOOTH EDGE

This function allows the user to smooth the edge of unfolded surfaces. eta/DYNAFORM will request the user to select the starting and ending points on the edge of the unfolded flange. The smoothed edge will be highlighted as shown in Figure 6.1.14. The CONTROL KEYS dialog box as illustrated in Figure 6.1.15 is displayed. The user has to select the next step from the options provided in the dialog box.

 

Figure 6.1.14  Smooth Edge

6

Figure 6.1.15  Control Keys dialog box

 

FINISH SMOOTH – Completes the smooth edge operation.

SMOOTH AGAIN – Performs the smooth edge operation again.

UNDO – Undoes the last smooth operation.

 

DELETE ORIGINAL FLANGES

The original flange surfaces will be removed from the database.

 

UNFOLD ANOTHER FLANGE

Continues to unfold another flange by repeating the steps previously mentioned.

 

·         Box Unfold

This function will unfold the selected radius surface to the plane where the base surface connected with one side of the radius surface locates. The feature of the suface connected with the other side of the radius surface remain unchanged. The dialog box is illustrated in Figure 6.1.16.

Figure 6.1.16  Box Unfold

Gap Tol.

This indicates the maximum gap allowed between the adjacent surfaces. If the gap between the adjacent surfaces is greater than the gap tolerance, these two adjacent surfaces are discontinuous.

 

Select Base Surface

Select a surface connected with the radius surface as the base surface. The radius surface is unfolded towards the plane where base surface locates. The base surface must be a flat plane.

 

Select Radius Surfaces

Select the radius surface connected with the base surface.

 

Delete Radius Surfaces

This button is enabled after the radius surface is unfolded, as illustrated in Figure 6.1.17. The unfolded radius surface is automatically included in the new part named UNFOLDED. The original radius surface is not deleted and is still included in the original part. Click this button to delete the original radius surface.

Figure 6.1.17  Delete radius surface

Apply

Click Apply button to unfold the radius surface and the surface connected with radius surface to the base surface.

 

Undo

Cancel the last operation.

 

Close

Close the Unfold Flange dialog box to exit this function.

 

The procedures of Box Unfold is as follows:

1. Select base surface, as illustrated in Figure 6.1.18.

Figure 6.1.18  Select base surface

2. Select radius surface, as illustrated in Figure 6.1.19.

Figure 6.1.19  Select radius surface

3. Click Apply to unfold, as illustrated in Figure 6.1.20. The unfolded radius surface is automatically included in the new part named UNFOLDED.

Figure 6.1.20  Unfolding result

NOTE: If the intersection line of radius surface and base surface is curve, the radius surface cannot be unfolded. The intersection line connecting the other side of radius surface and the surface must be a straight line, otherwise the radius surface still cannot be unfolded.

6.1.1.5  SURFACE EDIT

This function allows the user to edit surface by editing the control points on surface, as shown in Figure 6.1.21.

Figure 6.1.21  Surface Edit dialog box

After clicking on SELECT SURFACE button, the user can use cursor to select a surface on which the control mesh will be highlighted, as shown in Figure 6.1.22. Then the user can click DEFINE DIRECTION button to display the Define Vector dialog box. Please refer to Section 5.1.4 Shortest Curve for detailed operation.

Figure 6.1.22  Display Surface Control Mesh

Once the surface morphing direction is defined, the user can select one or multiple (SHIFT + left mouse button) control points by cursor and then drag one of the selected control points to edit surface, as shown in Figure 6.1.23.

 

(a)                                   (b)

Figure 6.1.23  Edit Surface

NOTE: The edited surface must be an non-trim surfaces.

6.1.1.6  SURFACE SPLIT

This function allows the user to split the selected surface into two surfaces at the specified line. Refer to Section 5.2.11 for detailed description of surface split.

6.1.1.7  MESH TOOL 1

This function is similar to the SURFACE MESH function as described in the Section 5.3.4 SURFACE MESH.

6.1.1.8  MODEL CHECK /REPAIR

All functions in the MODEL CHECK /REPAIR dialog box are described in Sections 5.5. Please refer to the section for a detailed description of these functions.

6.1.1.9  TOPOLOGY REPAIR 2

This function allows the user to auto repair topological structure that is not connected. After selecting the option, the program will pop up the dialog box in which the user can select the part to repair. The user can compare the original topological structure with the repaired as shown Figure 6.1.24.

a) Original topology                             b) Repaired topology

Figure 6.1.24  Auto topology repair

 

6.1.1.10  FILLET MESH define

The FILLET MESH function is used to generate fillet elements at the sharp corners of a part.  This function requires a relatively clean mesh without overlap elements or interior gaps, in additional to consistent element normal. The FILLET MESH dialog box as illustrated in Figure 6.1.25, provides options to locate and fillet sharp corners.

fillet

Figure 6.1.25  Fillet mesh dialog box

l   FEATURE LINES

ANGLE

This is the angle between the adjacent mesh normal. The default value is 20 º.

Entering the Fillet Mesh interface, the program will automatically seek the feature lines where the angle is larger than or equal to the angle criteria and highlight all features lines that meet the criteria as illustrated in Figure 6.1.26.

19

Figure 6.1.26  All feature lines

The user may enter other feature angle and click FIND button. The program will automatically seek the feature lines where the angle is larger than or equal to the angle criteria and highlight all features lines that meet the criteria.

 

ALL

Clicking this button, the program will highlight and select all the feature lines. Click APPLY button to fillet all the feature lines.

 

The program has already highlighted all the feature lines when entering the Fillet interface, so the ALL button is not enabled.

 

REMOVE

Click this button and select feature lines that do not require to be filleted in the display area by using the left button. Click the right button to cancel the last selection operation and click the middle button to confirm.

 

PATCH

This function is used to patch the un-integrated feature line. The operation steps are given below:

1. Click PATCH button to select an end point of the feature line, as illustrated in Figure 6.1.27.

16

Figure 6.1.27  Select the first point

2. Select nodes on the SHARP EDGE adjacent to this end point by sequence, as illustrated in Figure 6.1.28.

14

Figure 6.1.28  Select other nodes

 

3. Click the middle button to confirm. The patched feature line is illustrated in Figure 6.1.29.

 

15

Figure 6.1.29  Patched feature line

Note: When patching the feature line, the selected first point must be an end point of the feature line.

 

 

SELECT

This function enables the user to fillet the selected feature lines. Click SELECT button and select feature lines to be filleted in the display area by using the left button. Click the right button to cancel the last selection operation and click the middle button to confirm. Then, the program will highlight the selected feature lines, as illustrated in Figure 6.1.30. Click Apply button to fillet the selected feature lines.

 

18

Figure 6.1.30  Highlight the selected feature lines

 

l   PARAMETER

GLOBAL RADIUS

Define the global radius of all the feature lines and the default value is 3mm. After clicking the APPLY button, the program will use the global radius to fillet the feature lines whose constant radius and variable radius are not defined individually.

 

fillet2

Figure 6.1.31  Parameter

 

CONSTANT

This function is used to define the constant radius which is different from the global radius. Select Constant and click CHANGE RADIUS button. Use the left button to select feature lines in the display area. Click the right button to cancel the last selection operation. Click the middle button to confirm and enter the specified fillet radius in the displayed dialog box illustrated in Figure 6.1.32.

29

Figure 6.1.32  Change radius

Clicking OK, the program will show the radius of these feature lines in the display area, as illustrated in Figure 6.1.33.

28

Figure 6.1.33  Add constant radius fillet

VARIABLE

Select Variable and click CHANGE RADIUS. Once a feature line is selected, the dialog box illustrated in Figure 6.1.34 appears. Click Add button to add control points on the feature line, as illustrated in Figure 6.1.34. Set radius of the control point in the dialog box and the program automatically highlights the radius value of the control point, as illustrated in Figure 6.1.35.

6

Figure 6.1.34  Variable radius

20

Figure 6.1.35  Add control point

Click 7 button to delete the control point.

APPLY

Click APPLY button to fillet the selected feature lines according to the setup parameters.

EDIT

After creating the fillet, the feature line and fillet parameter are disabled, as illustrated in Figure 6.1.36(a). Clicking EDIT button, the Parameter is enabled and all the feature lines after filleting are highlighted, as illustrated in Figure 6.1.36(b). The user can change the global radius for the created fillet and add Constant or Variable radius. Once the edit is completed, the Create button is enabled. Click this button to fillet the feature line with new parameters.

fillet3       fillet4

(a)                                  (b)

Figure 6.1.36  Edit fillet

 

REMOVE

Click this button and all the filleted feature lines are highlighted. Select feature lines with fillets to be removed in the display area by using the left button. Click the right button to cancel the last selection operation and click the middle button to confirm. After confirmation, the Create button is enabled. Click this button to remove the fillets on these feature lines, as illustrated in Figure 6.1.37.

 

25     24

(a) Select feature line                                 (b) Result

Figure 6.1.37  Remove fillet

 

CANCEL

Click this button to cancel the operations for edit and remove, as illustrated in Figure 6.1.38.

34              33

(a)  Cancel edit operation                           (b) Cancel remove operation

Figure 6.1.38  Cancel

 

UNDO

Click this button to undo the fillet result.